this document proposes the software model for detection and analysis of cascading faults in the operation of large scale power grids. Using data mining technologies, probable patterns can be detected for faults and proper mitigation measures can be taken. Firstly, the fault is detected by checking the stability of system. Then event sequences are calculated to best approximate the fault node. Then by analyzing the severity of vulnerability and region in which vulnerability would occur, proper ICT Technologies can make operators aware about the faults. Hence, speeding up the existing mechanisms. This model aims to solve problem of detection more efficiently than existing systems.

1. IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 10, 2015 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 788
A Literature Review on Dry Wire Electrical Discharge Machining
Md. Najibullah1
Hardik A. Patel2
B C Khatri3
1,2
M.E Student (CAD/CAM) 3
Assistant Professor
1,2,3
Department of Mechanical Engineering
1,2,3
L. D College of Engineering, Ahmedabad
Abstract— EDM in gaseous media is one of the fastest
growing branches among institutions involved in the
research and development of EDM as green manufacturing
process Dry EDM is an environmental friendly machining
process were liquid dielectric fluid is replaced by gaseous
dielectric fluids. Present & past performance of dry EDM
process using various types of gases & their mixtures as
dielectric medium. Development of Dry EDM Technology
enhance the performance parameters such as material
removal rate (MRR), Low tool wear rate (TWR), thin recast
layer.
Key words: EDM, MRR, TWR
I. INTRODUCTION
In spite of the advantages, conventional EDM process has
certain limitations in Production application, including low
material removal rate, long lead time for reshaped tool
preparation, large tool wear, environmental concern caused
by toxic dielectric disposal, etc. One of the main sources of
environmental pollution during the machining processes is
the huge amount of supplied cutting fluids. The lubricants
are widely considered to be a benefit to cutting operations,
but despite the recognition of their advantages, it has also
been stated the negative impact and environmental issues
associated with their use. To avoid the problems caused by
the use of cutting fluids, considerable progress has been
made in the last years in the field of near-dry machining.
The conversion from conventional processes to minimal
quantity lubrication methods demands new tasks
classification in the tribology system in order to guarantee
the process. Dry wire EDM is one such method to reduce
dielectric disposal and to obtain a better finish machining at
low pulse discharge energy.
II. BASIC PRINCIPLE OF WEDM PROCESS
WEDM is a thermo- electrical process in which material is
removed by a series of sparks between work piece and wire
electrode (tool). The part and wire are immersed in a
dielectric (electrically non conducting) fluid, usually
deionized water, which also acts as a coolant and flushes the
debris away. The material which is to be cut must be
electrically conductive. In WEDM, there is no direct contact
between work piece and tool (wire) as in conventional
machining process, therefore materials of any hardness can
be machined [1] and minimum clamping pressure is
required to hold the work piece. In this process, the material
is eroded by a series of discrete electrical discharges
between the work piece and tool. These discharges cause
sparks and result in high temperatures instantaneously, up to
about 10000º C. These temperatures are huge enough to
melt and vaporize the work piece metal and the eroded
debris cools down swiftly in working liquid and flushed
away, the working principle is shown in the figure 1.
Fig .1: Working principle of WEDM
III. DRY WIRE EDM
Dry EDM, in which application of high flow rate gaseous
dielectric fluid, tends to eliminate the environmental
problem resulted from the liquid and powder mixed
dielectrics and also improves the machining performance.
Using inert gas to drill small holes (NASA, 1985) is the first
dry EDM attempt. Gas at high pressure is used as the
dielectric medium. In dry EDM, tool electrode is formed to
be thin walled pipe. The flow of high velocity gas into the
gap facilitates removal of debris and prevents excessive
heating of the tool and work piece at the discharge spots.
Tool rotation during machining not only facilitates flushing
but also improves the process stability by reducing arcing
between the electrodes The technique was developed to
decrease the pollution caused by the use of liquid dielectric
which leads to production of vapor during machining and
the cost to manage the waste. Dry EDM method with the
shortest machining time compare to oil die sinking EDM, &
lowest electrode wear ratio. Work removal rate also get
enhanced by dry EDM.
Fig. 2: principle of dry wire EDM

2. A Literature Review on Dry Wire Electrical Discharge Machining
(IJSRD/Vol. 3/Issue 10/2015/172)
All rights reserved by www.ijsrd.com 789
IV. PROCESS PARAMETERS AND PERFORMANCE MEASURES
The process parameters can be divided into two categories
i.e. electrical and nonelectrical parameters. Major electrical
parameters are discharge voltage, peak,current, pulse
duration and pulse interval, electrode gap, polarity and pulse
wave form. Main nonelectrical parameters are flushing of
dielectric, work piece rotation and electrode rotation.
Researches on flushing pressure reveal that it affects the
surface roughness, tool wear rate, acts as coolant and also
plays a vital role in flushing away the debris from the
machining gap. Major performance measures in EDM are
MRR, TWR and SR. For MRR, research work has been
focused on material removal mechanism and methods of
improving MRR. Similarly for TWR, research work on tool
wear process and methods of improvement in TWR has
been reported. Though EDM is essentially a material
removal process, efforts have been made to use it as a
surface treatment method and/or an additive process also.
Many surface Changes have been reported ever since the
process established itself in the tool rooms of manufacturing
industry.
V. DISCUSSION ON REVIEWED PAPER
C.C. Kao et,al. (2006) conducted dry EDM experiments on
thin work piece using air as dielectric fluid. They studied the
effects of spark cycle (T), spark on time (Ton), air flow rate,
work piece thickness, and type of material under wet and
dry EDM condition. The material removal rate (MRR) was
found to be low in dry EDM and could be slightly improved
by the use of air flow. Their results show that the increase in
work piece thickness and work piece melting temperature
had an adverse effect on the MRR. Which is further related
to the percentage of spark, arc, and short pulses. They also
observed that the deposition of debris in the groove cut by
dry EDM and found that for thick work piece, the groove
was totally blocked.
Fig. 3: Effect of thickness on MRR of AL 6061 for wet and
dry EDM.
K. Kanlayasiri, S. Boonmung(2007) studied the
effects of machining variables on the surface roughness of
wire-EDMed DC53 die steel. In this study, the machining
variables investigated were pulse-peak current, pulse-on
time, pulse-off time, and wire tension. They used Analysis
of variance (ANOVA) technique to find out the variables
affecting the surface roughness. Quantitative testing
methods on residual analysis were used in place of the
typical qualitative testing techniques. Results from the
analysis show that pulse-on time and pulse-peak current are
significant variables to the surface roughness of wire-
EDMed DC53 die steel. The surface roughness of the test
specimen increases when these two parameters increase.
They developed a mathematical model using multiple
regression method to formulate the pulse-on time and pulse-
peak current to the surface roughness. Eberhard Bamberg,
Dinesh Rakwalb (2007) investigated the electrical discharge
machining of gallium-doped p-type germanium with a
relaxation type pulse generator. They performed series of
experiments to establish the slicing rate for different types
and sizes of electrode wires. They also analyzed cut samples
using a 3D optical profiler and a scanning electron
microscope (SEM) for surface roughness and subsurface
damage. The samples were etched and analyzed for any
contamination using an X-ray energy dispersive
spectrometer (EDS). They also investigated the use of small
wire diameters (50–200_m) to enhance slicing rate and
surface characteristics.
Fig. 4: (a) Optical profile of a surface machined using
WEDM with surface roughness 3.06μm Ra.
(b) Optical profile of a WEDM machined surface after
etching with surface roughness 0.38μm Ra.
Jia Tao et,al.(2008) presented the experimental
studies by using oxygen gas and copper electrode for high
MRR in dry EDM and the nitrogen-water mixture and
graphite electrode for fine surface finish near-dry EDM.
Near dry EDM exhibits the advantage of good machining
stability and surface finish under low discharge energy
input. A 25−1 fractional factorial design is applied to
investigate the effect of discharge current, pulse duration,
and pulse interval on the MRR and surface finish in dry and
near-dry EDMs. Lower pulse duration and lower discharge
current are identified as key factors for improving the
surface finish in near-dry EDM. Oxygen demonstrated the
capability to promote MRR and exothermal oxidation in
both the dry and the near-dry EDM. Liquid phase dispersed
in the gas medium is hypothesized to enhance the electric
field and thus results in a large discharge gap distance and a
stable discharge at low energy input. Nitrogen and helium
gases could prevent the electrolysis and yield better surface
finish in near-dry EDM.

3. A Literature Review on Dry Wire Electrical Discharge Machining
(IJSRD/Vol. 3/Issue 10/2015/172)
All rights reserved by www.ijsrd.com 790
Fig. 4: Effect of the discharge current on high energy input
dry EDM with
oxygen , ti=4 _s, t0=8 _s, ue=60 V, and ui=200 V…
Sourabh K. Saha, S.K. Choudhury(2009)
experimentally obtained polynomial models for MRR and
Ra and they used it for optimizing the dry EDM process.
They performed Process optimisation using Non–dominated
Sorting Genetic Algorithm (NSGA II) to obtain the Prato–
optimal front. Based on the optimization results and the
subsequent focused experiments, they concluded that high
air pressure and high spindle speed combination is
favourable for obtaining both a high MRR and a low Ra.
Such a combination of these input parameters leads to a
higher flushing efficiency. Finish machining region (low
Ra) was obtained for low current, high pulse–on time and
low duty factor values. Rough machining region (high
MRR) was obtained for high current, low pulse–on time and
high duty factor values. Y. Perez Delgado et,al. (2010)
performed linearly reciprocating sliding wear experiments
on WC-Co and WC-Ni cemented carbides and ZrO2-
WC,ZrO2–TiCN and ZrO2–TiN composites with different
surface finishes corresponding to sequential wire-EDM
using an ASTM G133 system with WC-6 wt.% Co
cemented carbide as counter body. 3D topography mapping
and volumetric quantification of the wear tracks was
obtained by surface profilometry. Scanning electron
microscopy (SEM) and energy dispersive X-ray (EDX)
spectroscopy were employed to observe morphological and
chemical features of worn surfaces and wear debris. The
identified wear mechanisms are discussed. Monica Balas
et,al.(2011) evaluated the heat affected zone in sub-surface
layers of the samples made by technology of wire electrical
discharge machining. The samples produced on EDM-WC
machine SP 640-P from two different materials, steel and
tungsten carbide. The cutting tool was wire brass electrode
of 0.25 mm diameter. They determine experimentally and
with FEA the influence of the heat affected zone and micro-
hardness. They found that HAZ depth increasing with the
current intensity and high temperature during the process
affects material micro hardness of manufactured surfaces. M
R Shabgard et,al.(2011) presented a finite element model
(FEM) to model temperature distribution for AISI H13 tool
steel work piece in electrical discharge machining (EDM) at
different machining parameters (pulse current, pulse on-
time, temperature-sensitive material properties, size of heat
source, and material flushing efficiency). Scanning electron
microscopy (SEM) with energy dispersive x-ray (EDX) and
micro-hardness tests being used by them to validate
accuracy of FEM predictions. Increasing pulse on-time leads
to a higher depth of heat affected zone and increasing pulse
current results in a slight decrease of depth of heat affected
zone.
Xiaodong Yang et,al.(2012) presented their
investigation considering the relative motion between the
wire electrode and the work piece, they established heat
transfer model of wire electrode under moving heat source,
and they simulated temperature field of wire electrode in
single pulse discharge by FEM. Their results indicated that
the size of the melted zone along the wire electrode axial
direction increased remarkably while the depth size, the
width size and the volume of the melted zone reduced
apparently when the wire running speed increased. They
concluded that the high relative speed between the wire
electrode and the work piece is beneficial to reduce the wire
electrode wear in radial direction. Furthermore, when the
wire running speed is higher than a certain value, the
discharge column will slide over the wire electrode surface
before the wire material reaches its melting point, thus the
melting and ablation of the wire electrode material does not
happen, which can almost realize no wire electrode wear.
Danial Ghodsiyeh,et al.(2013) studied the research
trends in WEDM and found that the research trends in
WEDM on relation between different process parameters,
include pulse on time, pulse off time, servo voltage, peak
current, dielectric flow rate, wire speed, wire tension on
different process responses include material removal rate
(MRR), surface roughness (Ra), sparking gap (Kerf width),
wire lag (LAG) and wire wear ration (WWR) and surface
integrity factors, different types of WEDM methods

4. A Literature Review on Dry Wire Electrical Discharge Machining
(IJSRD/Vol. 3/Issue 10/2015/172)
All rights reserved by www.ijsrd.com 791
introduced and discussed. In addition the paper highlights
different modeling and optimization methods and discussed
their advantage and disadvantage. There are also some
recommendations about the trends for future WEDM
research.C.D. Shah, J.R.Mevada, B.C.Khatri(2013)
conducted experiment on Inconel-600 material in Wire Cut
EDM and they developed RSM models, the interesting
conclusions were drawn from their studies. The effects of
Pulse On time, Pulse Off time, Peak Current, Wire Feed rate
setting are experimentally investigated in machining of
Inconel-600 using CNC Wire-cut EDM process. The level
of importance of the machining parameters on the material
removal rate is determined by using ANOVA and it is
shown that Pulse on, Pulse Off, Peak current are most
significant. An optimum parametric combination for the
maximum material removal rate was obtained by using
Signal-to-Noise (S/N) ratio. Improved S/N ratio and
conformation test indicated that it is possible to increase
material removal rate by using the proposed statistical
technique. They developed mathematical model, i.e.
Response surface Model for the performance characteristic
such as Material removal rate (MRR) in the CNC Wire-cut
EDM process is successfully proposed for the proper
selection of the machining parameter. G. Skrabalak, J.
Kozaka, M. Zyburaa(2013) concluded that the EDM milling
process conducted in air and sulphur hexafluoride is very
effective method of machining. It is especially suitable for
micromachining of complex cavities and shapes. Due to the
negligible tool wear ratio it is more precise than EDM
milling in kerosene. Comparative tests of machining in
gaseous dielectrics (gas flow rate 13 l/min) and kerosene
(work piece submerged + forced side flow, no through
electrode flow) were performed for the parameters such as
Free run voltage 160V, reference voltage (used for process
controller) 50V, Pulse ON/OFF time Peak current 1A,
Electrode rotation 5000rpm.Preparing tool paths is much
easier in this kind of EDM machining.
Danial Ghodsiyeh,et al.(2013) studied the research
trends in WEDM and found that the research trends in
WEDM on relation between different process parameters,
include pulse on time, pulse off time, servo voltage, peak
current, dielectric flow rate, wire speed, wire tension on
different process responses include material removal rate
(MRR), surface roughness (Ra), sparking gap (Kerf width),
wire lag (LAG) and wire wear ration (WWR) and surface
integrity factors, different types of WEDM methods
introduced and discussed. In addition the paper highlights
different modeling and optimization methods and discussed
their advantage and disadvantage. There are also some
recommendations about the trends for future WEDM
research.C.D. Shah, J.R.Mevada, B.C.Khatri(2013)
conducted experiment on Inconel-600 material in Wire Cut
EDM and they developed RSM models, the interesting
conclusions were drawn from their studies. The effects of
Pulse On time, Pulse Off time, Peak Current, Wire Feed rate
setting are experimentally investigated in machining of
Inconel-600 using CNC Wire-cut EDM process. The level
of importance of the machining parameters on the material
removal rate is determined by using ANOVA and it is
shown that Pulse on, Pulse Off, Peak current are most
significant. An optimum parametric combination for the
maximum material removal rate was obtained by using
Signal-to-Noise (S/N) ratio. Improved S/N ratio and
conformation test indicated that it is possible to increase
material removal rate by using the proposed statistical
technique. They developed mathematical model, i.e.
Response surface Model for the performance characteristic
such as Material removal rate (MRR) in the CNC Wire-cut
EDM process is successfully proposed for the proper
selection of the machining parameter. G. Skrabalak, J.
Kozaka, M. Zyburaa(2013) concluded that the EDM milling
process conducted in air and sulphur hexafluoride is very
effective method of machining. It is especially suitable for
micromachining of complex cavities and shapes. Due to the
negligible tool wear ratio it is more precise than EDM
milling in kerosene. Comparative tests of machining in
gaseous dielectrics (gas flow rate 13 l/min) and kerosene
(work piece submerged + forced side flow, no through
electrode flow) were performed for the parameters such as
Free run voltage 160V, reference voltage (used for process
controller) 50V, Pulse ON/OFF time Peak current 1A,
Electrode rotation 5000rpm.Preparing tool paths is much
easier in this kind of EDM machining.
R. Rotha et,al.(2013) analysed MRR and discharge
behaviour of DEDM for different more or less oxidizing
gases. Current specific and power specific MRR are
presented and hypothesis of the ruling mechanisms
regarding the influence of oxygen in DEDM are elucidated.
The influence is given by two different mechanisms. The
first one occurs only at high oxidation capability of the
flushing gas acting on the stability of the process. The
second effect of the oxidation results in different specific
MRR values and saturates already with little oxidation
capability of the flushing gas

5. A Literature Review on Dry Wire Electrical Discharge Machining
(IJSRD/Vol. 3/Issue 10/2015/172)
All rights reserved by www.ijsrd.com 792
Fig. 5: current specific material removal rate for different
flushing gases
Prof. Chirag P. Patel et.al, (2013) suggested that
fewer tool electrodes are required in dry EDM due to lower
tool wear. The total machining time for dry EDM may then
be lower than die-sinking EDM. In the process of UEDM in
gas, the increase of MRR is at the expense of surface
roughness. It was found that discharge current, duty factor,
air pressure and spindle speed are the significant factors
which affect MRR and MRR increases with an increase in
any of these factors. Genetic Algorithm (GA) based multi-
objective optimization for maximization of MRR and
minimization of Ra has been done by using the developed
empirical models Sushil Kumar Choudhary, R. S
Jadoun(2014)find the following characteristics: Dry EDM is
eco-friendly machining. Pollution is reduced by use of gas
instead of oil based dielectric. Harmful & toxic fumes are
not generated during machining. Material removal rate
(MRR) &electrode wear ratio (EWR) also get enhanced by
dry EDM. Hollow tube and eccentric drilled hole type
electrode are reported to have positive impact on MRR due
to improved flushing condition.. Shaaz Abulais (2014) in his
study of current research trends in WEDM he found the
characteristics of dry EDM and concluded as tool electrode
wear is negligible for any pulse duration. The processing
reaction force is much smaller than in conventional EDM. It
is possible to change supplying gas according to different
applications. The residual stress is small since the melting
solidification layer is thin. Working gap is narrower than in
conventional EDM. The process is possible in vacuum
condition as long as there is a gas flow. The machine
structure can be made compact since no working basin, fluid
tank and fluid circulation system needed. G.M.Pradeep,
M.S.Heaven Dani (2015) presented a literature survey on
the use of water based gaseous dielectric medium that
provide an alternative to dielectric fluids. Gaseous
dielectrics such as oxygen, Helium, Argon may also be the
alternative. From the literature review, with a help of
gaseous dielectric mediums like oxygen, air, argon, helium,
we can reduce the environmental pollution and also the
machining time is reduced, surface roughness of the work
piece material is increased.Ibrahem Maher et, al. (2015)
presents an experimental investigation of wire electric
discharge machining (WEDM) for improving the process
performance. The effects of the machining parameters were
investigated on the machining performance. ANFIS was
used to predict the cutting speed, surface roughness and heat
affected zone in WEDM. The predicted cutting speed,
surface roughness, and heat affected zone were compared
with measured data, and the average prediction error for
cutting speed, surface roughness, and heat affected zone
were 3.41, 3.89, and 4.1 respectively
VI. CONCLUSION
Dry EDM is eco-friendly machining. Pollution is reduced by
use of gas instead of oil based dielectric because harmful &
toxic fumes are not generated during machining.In dry
WEDM material removal rate &electrode wear ratio
improves. This machining process should be supported and
more research should be carried out since it helps to save the
environment. Recent enhancement in various parts of EDM
that reflect the state of the art in these processes are
presented in this review paper. Researcher works on
increasing of material removal rate (MRR),lowering of tool
wear rate (TWR),enhance Surface Quality (SQ) by study
and experimentaion. Numerous methods like Vibration,
rotary and Vibro-rotary mechanism based EDM, water
based EDM has been incorporated for increase of EDM
efficiency, Dry EDM use of gas instead of oil electrolyte,
PM-dielectric Electric Discharge Machining. It also plays a
significant role in medical, optical, Jewellery, automotive
and aeronautic industry & making a various mechanical
component in manufacturing industries.
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